Aco Polymer Products 74004 Installation guide

Brand: Aco Polymer Products

Model: 74004

Type: Installation guide

EXPANSION JOINT TO

ENGINEER’S DETAIL

CONCRETE

BEDDING LAYER

SOIL

Site Installation Manual

Polymer Concrete Drain Systems

ACO DRAIN

Re-order DL016

(800) 543-4764

www.ACODrain.us

POLYMER CONCRETE

ACO Drain consists of a full range of

modular channels with captive grates;

Systems include catch basins, end caps,

and other accessories.

When installed correctly, ACO Drain

products are designed to withstand a

variety of loadings as classied by

EN 1433 (The only standards specically

for trench drain systems).

Getting Started

Contents

Getting Started 2

Health and Safety 3

Installation Sections 4

1. Excavation 6

2. On-site Fabrications

- Cutting channels & Tee junctions 7

- Miters, Corners, Bends & Radius 8

3. Pipe Connections 9

4. Connection with

Underground Piping 10

5. Positioning of Channels

- Patty Method 11

- Hanging Methods 12

- Installation Devices 14

6. Catch basin blanking plates 15

7. Pouring Concrete 16

8. Pavement Finishing

- Concrete 17

- Asphalt 18

- Brick Pavers 18

9. Fit / Remove Grates 19

10. Final Inspections & Maintenance 22

Polymer concrete products should be

handled with care as they can be

damaged by impact from other products,

or machinery.

Typical equipment necessary for

installation may include:

 Excavating equipment

 String-line and laser level

 Measuring tools

 Masonry drill, grinder and/or saw

 Rubber mallet

 Concrete - 4,000 psi recommended

compressive strength

 Gloves, respirator and eye protection

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POLYMER CONCRETE

Commercial Trench Drains

Health and Safety

Polymer concrete

Products are manufactured using

synthetic resin, mineral aggregates and

curing agents.

Main hazards include:

Abrasive damage to hands.

Inhalation of dust from grinding, cutting,

or drilling.

Grinding, cutting, etc. may project small

fragments.

Gloves, eye protection and a respirator

should be worn to avoid these hazards.

Metal grates

Grates are typically made from either cast

or fabricated metals.

Main hazards include:

Abrasive damage/cuts to hands.

Inhalation of dust from grinding

or cutting.

Grinding, cutting, etc. may generate

sparks; ammable items should be

removed from area.

Gloves, eye protection, and respirator

should be worn to avoid these hazards.

Operations should be conducted away

from areas of re or explosion hazard.

Make sure arrows molded on sides

of channel all point in the intended

direction of ow (outlet point).

Male

Female

male end

(down stream)

female end

(up str

eam)

Flow direction

indicator arrow

Channel sequence

number

Only required for

QuickLok grates

Supplied

by others

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POLYMER CONCRETE

These illustrations are a guide

for typical ground conditions

only. Engineering advice

should be taken.

Refer to www.ACODrain.us for

further information.

An installed ACO Drain System

should incorporate the following:

Correct grate type.

Correct channel type and size.

Recommended grade 4,000 psi

compressive strength cement

concrete surround.

Concrete surround dimensions

are minimum dimensions and

engineering advice should be

taken to conrm appropriate for

the specic project.

Concrete surround should

typically be the same thickness

as the concrete slab.

Poor site conditions and low load

bearing pavement will require

an increase in these dimensions

to meet both vertical and lateral

loads.

Reinforcing steel may be required

within the slab and around the

trench drain - engineering advice

should be sought to determine

bar size and conguration.

For Load class F applications,

ACO recommends using the

concrete anchors offered with

PowerDrain.

See table

pg 6

See table pg 6

Pavers

Subgrade

See table

pg 6

See table pg 6

Pavers

Subgrade

Installation Sections

Pavers - EN 1433 Class A - F

Pavers - EN 1433 Class A - C only

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POLYMER CONCRETE

Commercial Trench Drains

See table

pg 6

See table pg 6

Asphalt

Subgrade

Concrete

See table

pg 6

See table pg 6

Subgrade

Concrete

Expansion

joint to

engineer’s

details

See table

pg 6

See table pg 6

Subgrade

Asphalt

Concrete

Asphalt - EN 1433 Class A - C only

Concrete - EN 1433 Class A - F

Asphalt - EN 1433 Class A - F

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POLYMER CONCRETE

C. For sloped systems, excavate base

of trench to roughly follow fall of

trench run.

Ensure loose material is removed from

trench and base is well compacted.

Run string line, or laser, at nished

surface level along full length of proposed

trench run to ensure trench is installed to

grade.

In concrete pavements ensure an

allowance is made for expansion/isolation

joints, if necessary, to allow movement

due to thermal expansion/contraction.

Load Cl A B C D E F

4”

channel

4” 4” 6” 6” 8” 12”

8”

channel

4” 4” 6” 8” 8” 12”

12”

channel

4” 6” 6” 12” 12” 12”

Excavate trench to accommodate drain

system. Excavations must be made about

the center line of proposed drainage run

and catch basin.

Trench must be big enough to

accommodate each of the following:

A. Channel/catch basin width and

depth dimensions.

B. Concrete surround dimensions*.

Excavation

ACO Drain channel

Finished surface

See table below

for recommended

dimensions

Form board if requiredTrench profile

10,

010, 010, 010, 010, 010, 010, 010, 010

Sloped

system

Constant

depth

system

Concrete Surround Dimensions* (x)

NOTE: Check product literature for

overall product depth. Add additional

measurement for concrete surround

from table at left.

* These dimensions are recommended

minimums only, based on recommended

4,000psi concrete. Ground conditions

will affect actual dimension required;

engineering advice should be sought.

Concrete surround should be same

thickness as surrounding slab depth.

(800) 543-4764

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POLYMER CONCRETE

Commercial Trench Drains

When cutting channels and/or grates,

gloves, protective eye wear and respirator

or mask are recommended.

Cutting channels

Required to form miters, tee junctions

and non-standard lengths. Most

fabrications can be completed on site.

ACO offers a custom fabrication service

for more complex fabrications. Contact

ACO Technical Department for further

information.

Channels should be cut with a masonry or

diamond disc saw. Grates should be cut with

band saw, or similar, with suitable blade.

A 2 - part rigid resin glue (ACO Bond) can

be used to bond cut surfaces together, if

required.

If corrosive liquids are transported in

trench, joints should be properly sealed.

Ensure the sealant/adhesive used is

chemically resistant.

On-Site Fabrications

Tee Junctions

Tee junctions are when an opening is cut

into the side of one channel and another

channel is butted up to this opening.

All half meter channels provide molded

guide for side removal. Other channels;

mark area in channel wall to be removed

by butting channels together and marking

prole of interior of channel.

NOTE: Edge rail should be left intact

to provide additional strength and

seating for grate.

Cut opening

on the side

of the channel

Side wall cut-out

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POLYMER CONCRETE

Miters

Corners

Formed by cutting channels to required

angle and butting together.

For heavy duty applications (D-F), mitered

grates are not recommended. A tee joint is

suggested to give grate maximum support.

Channels are mitered;

grates are shown as tee joint.

Channels mitered

at 45° angle

On-Site Fabrications

Radius

Channels can be installed to slight curves

by leaving an acceptable gap at the

channel joints (acceptable gap to be

approved by client).

Tight curves/bends

For tight curves or bends, miter cut end of

each channel and grate to required angle.

Results in a neat nish at joint

Using half meter non-sloping channels, allows more ’segments’ to be added to the radius;

the gap between channels is reduced, or alternatively a tighter radius can be achieved.

Miter each

channel end

Acceptable gap

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POLYMER CONCRETE

Commercial Trench Drains

Channel - knockout

Stand channel upright holding outlet

end in hand to absorb impact

and prevent cracking. Using

hammer, from inside of channel,

carefully tap out required area

following around inside of symbol.

Knock-out symbol

Tap here

Pipe Connections

Removal of knockout, or cut hole:

1. Identify and mark area to be removed.

(Bracing may be necessary).

2. Material removal:

Catch Basin - cut-out

Use cut-off tool, reciprocating saw

or band saw to cut opening for

required pipe size and location.

3. Use a grinder to dress or enlarge hole

for proper pipe insertion.

4. A pipe may be tted into hole

using appropriate sealant/adhesive.

If corrosive liquids are transported

in trench, ensure sealant or adhesive

is chemically resistant.

3. Attach outlet pipe using coupler,

if required seal using appropriate

sealant/adhesive. If corrosive liquids

are transported in trench, ensure

sealant or adhesive is chemically

resistant.

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POLYMER CONCRETE

Channels may be connected directly to

underground piping via:

1. End cap outlets (horizontal outlet).

Connection with Underground Piping

2. Vertical knockouts (penetrations

on underside of channel).

3. In-line catch basin.

4. Catch basin.

Connecting channels to catch basins

Catch basins have guides for channel

connection at depths corresponding to

invert level of designated channel units

(10, 20, 30, 40).

In-line catch basins - cut out black end

material at required channel height. Seal

joint with exible sealant. See page 15 for

end blanking plate details, if required.

600 Series catch basins - stitch drill out

polymer concrete panel (100 systems) or

cut out black end material (200 systems)

at required height. See page 15 for end

blanking plate details, if required.

(800) 543-4764

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POLYMER CONCRETE

Commercial Trench Drains

Male

As per table (pg. 6)

Female

Work away from outlet

ACO DRAIN

Concrete key

Avoid concrete/dirt at joint

Positioning of Channels

Start with outlet. Ensure string-line, or laser

is set at top edge of required channel height.

Common methods of positioning channels:

include:

1. Patty Method

2. Hanging Method

3. Installation Device

1. Patty Method

a) Set catch basin (or outlet channel) on

bed of concrete to required height

(see page 6 for concrete dimensions).

Connect and seal outlet pipe.

b) Using low slump concrete, create

‘patties’ at intervals to support channels.

Allow two patties per channel, spaced

such that no concrete material is

trapped in joint, creating gaps.

Note: Patties should be sized to

provide required concrete surround

(see page 6).

c) If channels are to be sealed, roughen

ends and use a exible sealant -

check chemical compatibility, if

required.

d) Lower channel vertically onto ‘patties’

and position to correct height and

alignment ensuring ‘tight’ connection

to previous channel.

e) Add concrete on top of ‘patty’ to cover

concrete ‘keys’ on side of channel - this

prevents movement, or oating, during

concrete pour.

f) Continue to lay channels until end of

run or next catch basin is reached.

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POLYMER CONCRETE

2 x 4’s (anchoring

fasteners should be

used to prevent floating)

Cross

bar

Spacers allow

concrete surface

finishing at

supports

Use shims to position

channel correctly

relative to slab

Finished height

Plywood bracing

Plywood

bracing

Threaded rod

100 - L=4.64” H=0.50”

200 - L=8.58” H=0.75”

300 - L=12.52” H=0.75”

1.25”

Saw cut

2 x 4

supports

Anchoring

fasteners

to prevent floating

Spacer

Positioning of Channels - Hanging Methods

Retrot installations - use existing slab to

anchor supports. Alternatively, form boards

can also be used.

2.i Bolting Method - DrainLok/

QuickLok

K100, K200, K300, H100, H100K, H200K,

H300K will require a long threaded rod and

cross bar to t in the locking bar recesses.

a) Cut 2 x 4’s to length to span excavated

trench or form boards (minimum 2 per

channel - K200 & K300 will require 3 - 4).

Cut ‘spacers’ to ‘lift’ supports above

nished level. Cut bracing to t into

grate rebate.

b) Drill 5/8” diameter holes in the center

of each 2 x 4 and spacer. Drill holes in

center of bracing at 19.69” (500mm)

centers to match locking positions.

c) Tighten 5/16” x 18 threaded rod

through center of each cross bar. Fit

cross bars into channel recesses.

d) Slide bracing, spacers and 2 x 4’s over

threaded rods.

e) Lower channels into excavated trench,

adjust to required position and height.

Shims may be required beneath 2 x 4’s

to achieve required height and ensure

channels are level.

f) If channels are to be sealed, roughen

ends and use a exible sealant - check

chemical compatibility, if required.

g) Nail or anchor 2 x 4 supports securely to

slab/form boards. This ensures channels

are held securely during concrete pour.

Retrot installation

New installation

Threaded rod and bar

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POLYMER CONCRETE

Commercial Trench Drains

Positioning of Channels - Hanging Methods

Retrot installations - use existing slab

to anchor supports. Alternatively, form

boards can also be used.

2.ii Bolting Method - PowerLok

S100K, S200K, S300K, H100SK,

H200SK, H300SK will require M10 - 1.5

x 120mm bolts to screw into widgets in

edge rail of channel. This allows the bolt

to pass through the spacers, 2 x 4’s and

into widget nut.

a) Cut 2 x 4’s to length to span excavated

trench or form boards (minimum 2 per

channel - S200K & S300K will require

3 - 4 per channel). Cut ‘spacers’ to

‘lift’ supports above nished level.

b) Drill two 5/8” diameter holes in the

2 x 4’s and spacers - width to match

widgets in channel rail.

c) Using M10 - 1.5 x 120mm bolts with

washers, bolt 2 x 4 and spacer to

channel - do not overtighten. If using

torque wrench do not set higher than

15ft. lbs.

d) Lower channels into excavated trench,

adjust to required position and height.

Packing material may be required

beneath 2 x 4’s to achieve required

height and to ensure channels are level.

e) If channels are to be sealed, roughen

ends and use a exible sealant - check

chemical compatibility, if required.

f) Nail or bolt 2 x 4 supports securely

to slab/form boards. This ensures

channels are held securely during

concrete pour.

Widgets in edge rail

Saw cut

2 x 4

supports

Anchoring

fasteners

to prevent floating

Spacer

2 x 4 (anchoring fasteners

to prevent floating)

Finished height

Spacers allow

concrete surface

finishing

New installation

Retrot installation

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POLYMER CONCRETE

Positioning of Channels - Installation Devices

A clamping system that ts around the

proled end details is available to support

the channel in place and allow a single

pour if required.

Rebar is used to achieved correct height.

One device per joint is required, including

start and end of the run.

100, 200 & 300 wide versions available.

Parts are supplied with a full detailed

instruction sheet

Adjustable clamp fits

into recesses on

side of channels

Rebar allows

easy height

adjustments

1. Create required width template using

timber sheet or similarly suitable rigid

material. Diagrams can be printed

from the ACO website.

www.ACODrain.us/technical.html

2. Start at outlet. Drive #4 or #5 rebar

into ground to hold three installation

devices spaced using ACO template.

Screw installation device to rebar at

required height.

3. Set channels in position but do not

lock into position until next channel is

in place as his allows some exibility

and movement.

4. Move template and set rebar in place

- always allow two sets of rebar to be

installed before placing channels to

enable template to be moved to next

position.

5. When ready to lock channels in place,

ensure channel is positioned such

that the xed clamp ts into recess in

channel end.

6. Push adjustable clamp tight onto

other side of channel.

7. Tap metal wedge into slot to lock

adjustable clamp in place, locking

channel joint closed.

5. Repeat for additional channels.

6. Check channels are at required level -

adjust using screws on rebar.

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POLYMER CONCRETE

Commercial Trench Drains

All in-line catch basin tops and the 200mm

and 300mm wide 600 Series catch

basin tops have open end rails to allow

connection of channels both ends.

Blanking plates are supplied to prevent

concrete ingress during the concrete

pour when channel connection does not

close end rail openings. Blanking plates

match catch basin edge rail - galvanized,

stainless, or coated black steel to match

color of iron rails.

To close off the entire opening where no

channel is connecting, simply push down

over the polymer concrete bridge.

Catch Basin Blanking Plates

Push blanking plate down over

the polymer concrete bridge

Where a channel is connecting into a

Series 600 catch basin the blanking plate

can be cut, removing the center where the

channel connects.

Blanking plate cut down to

fit channel opening.

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POLYMER CONCRETE

Concrete should be poured evenly (both

sides of channel) and carefully to avoid

dislodging channels. A wand type concrete

vibrator should be used to ensure concrete

distributes evenly around channels.

If ‘cold joints’ are a concern, engineering

advice should be sought to determine

single pour procedure.

Channel Anchors

For Load class F applications, ACO

recommends using the concrete anchors

offered with PowerDrain. Metal anchors are

attached through punched out hole in edge

rail - see Technical Bulletin for details.

Channel Bracing

To prevent channel wall and joints from

distortion by weight of concrete, grates

or 3/4” plywood sections (cut to create

a snug t) should be placed in the grate

rebate of channel.

If grates are used, they should be suitably

protected from concrete contamination

during concreting (wrapped in plastic

or masking tape) and should be laid to

bridge channel joints to aid alignment.

Shims (or washers) should be placed

along one side to maintain a clearance

gap.

Concrete Pour

If using closing/outlet end caps with

channels 1-15 remove unused spigot to

ensure sufcient concrete coverage.

To prevent concrete from lling channel

body, cover open areas with plywood or

similar. (Bracing should sufce).

Recommended that concrete have

compressive strength of 4,000 psi.

If using hanging method, and channels

are securely in position, rst concrete

lift should come approximately 2 inches

(50mm) up sides of channels.

Once rst lift has hardened, remaining

concrete surround can be poured.

Pouring Concrete

Shim

Second lift

First

lift

Anchor

Screw

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POLYMER CONCRETE

Commercial Trench Drains

Finished concrete

to have slight

slope down to

channel

Approx.

45°

Concrete

1/8”

Grating

Transverse

joint

Original slab

Align with channel joint

Expansion

joint

Pavement Finishing - Concrete

To nish installation, trowel concrete at

and taper down to channel edge. The

top of adjacent pavement must be above

the grate level (approximately 1/8”), this

ensures all liquids drain into the channel.

Once concrete has cured 24 hours,

remove bracing and/or grate protection.

Fit grates - see page 19/21.

Expansion joints

Transverse joints (perpendicular to the

channel) are required to prevent surface

cracking in the slab. Such joints should

be positioned at channel joints to prevent

channels from cracking. If such spacing is

not possible, a cut must be made at the

appropriate location through the channel

and sealed with exible sealant.

Longitudinal expansion/isolation joints

should be continuous and exible. They

must be provided between the concrete

surround and surrounding slab and may

be varied to suit concrete surround width

by up to a meter (3 feet) from the channel.

If the joint is dowelled, debonding should

be provided. ACO recommends seeking

engineering advice.

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POLYMER CONCRETE

Pavement Finishing - Asphalt

For applications where asphalt can be

applied directly up to channel edge, see

appropriate channel/installation detail.

ACO recommends for applications over

Class C a full concrete surround be used.

See page 6 for concrete haunch details.

CAUTION: To prevent damage to

channels and grates, protect channel

between concrete pour and application of

asphalt and when rolling asphalt.

Asphalt must be above grate level by

approximately 1/8”, this ensures all liquids

drain into channel.

Once pavement is nished, remove

bracing and/or grate protection. Fit grates

- see pages 19/21.

Pavement Finishing - Brick Pavers

For applications where brick pavers can

be installed directly up to channel edge,

see appropriate channel/installation detail.

ACO recommends for applications over

Class C a full concrete surround be used.

See page 6 for concrete haunch details.

Brick pavers adjacent to channel MUST

be fully bonded to concrete haunch. This

prevents movement of bricks and possible

damage to channel. Subsequent pavers

can be bedded on compacted sand.

Bricks must be above grate level by

approximately 1/8”, this ensures all liquids

drain into channel.

Once pavement is nished, remove

bracing and/or grate protection. Fit grates

- see pages 19/21.

Concrete

1/8”

Grating

First course bonded

to concrete haunch

Concrete

1/8”

Grating

Approx.

45°

Finished asphalt

to have slight

slope down to

channel

Base

Course

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POLYMER CONCRETE

Commercial Trench Drains

Fitting/Removing Grates

DrainLok Grates

1. DrainLok does not require a locking

bar - clips in the grate t into recesses

in the steel edge rail to hold grates

securely in place.

2. To install grate, align clips in underside

of grate with recesses in edge rail. Push

down/stand on grate until clicks into

position.

3. To remove rst grate, insert removal

tool under grate bar, pull up sharply.

Subsequent grates can be removed by

hand - Grip end of grate and lift sharply.

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POLYMER CONCRETE

QuickLok Grates

1. Fit QuickLok bar in channel wall

recesses by rotating clockwise.

K100 - Use hammer to tap into place,

so that serrated ends grip in recess.

K200/K300 - Use plastic safety clip

to hold bar in place.

2. To install grate, align stud directly over

locking bar. Push down/stand on grate

until clicks into position.

3. To remove rst grate, insert removal

tool under grate bar, pull up sharply.

Subsequent grates can be removed by

hand - Grip end of grate and lift sharply.

4. To remove K100 bar, insert screwdriver

into hole at end of bar - lever back

serrated section to loosen. K200/K300

- remove plastic clip to remove bar.

Fitting/Removing Grates

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Aco Polymer Products 74004 Installation guide

Aco Polymer Products 74004 Installation guide

Aco Polymer Products 74004 Installation guide

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